Fire Safety of Polymer Nanocomposites: An In-Depth Analysis Based on Functional Mechanisms

Polymeric materials face serious fire-safety challenges in construction, electrical and electronic devices, and aerospace because of their high heat release, melt-dripping tendency, and severe smoke and toxic emissions during burning. This review systematically summarizes the roles of nanofillers in the fire safety of polymer nanocomposites across three interconnected levels: functional mechanisms, regulatory factors, and macroscopic fire behavior. It focuses on four main mechanisms, namely physical barriers, catalytic charring, free-radical scavenging, and rheological network reconstruction, and further discusses how filler geometry, loading level, interfacial compatibility, dispersion state, and spatial orientation regulate fire-safety performance. By linking these factors to time to ignition, thermal stability, heat release, flame spread, and smoke emission and toxicity, the review clarifies the intrinsic structure-mechanism-property relationships. Current studies indicate that the fire-safety improvements provided by nanofillers do not arise from any single effect, but from their coupled regulation of heat transfer, mass transfer, radical reactions, and high-temperature rheology throughout thermal degradation, ignition, heat release, flame spread, and smoke and toxic-gas emission. Remaining challenges include the lack of unified evaluation criteria, limited in situ mechanistic evidence, and insufficient application-oriented rational design. Future work should establish verifiable, comparable, and predictive structure-mechanism-property relationships for polymer nanocomposites.